Method of laser-assisted metal-plastic hybrid 3D printing and multilayered structure by using thereof

Abstract

Provided is a method of producing a metal-plastic multi-layered hybrid structure by using laser three-dimensional (3D) printing, the method including printing a metal structure on a substrate by using a first laser, patterning an upper surface of the metal structure by using the first laser, printing a polymer bonding layer on the patterned metal structure by using the first laser, and printing a polymer structure on the polymer bonding layer by using a second laser having a wavelength longer than a wavelength of the first laser, wherein the printing of the polymer bonding layer includes forming an intermediate phase at an interface between the metal structure and the polymer bonding layer. A layered structure produced using the above method may include the intermediate phase having the effect of an oxygen inclusion connecting a metal and a polymer.

What is claimed is: 
     
       1. A method of producing a metal-plastic multi-layered hybrid structure by using laser three-dimensional (3D) printing, the method comprising:
 printing a metal structure on a substrate by using a first laser; 
 patterning an upper surface of the metal structure by using the first laser; 
 printing a polymer bonding layer on the patterned metal structure by using the first laser; and 
 printing a polymer structure on the polymer bonding layer by using a second laser having a wavelength longer than a wavelength of the first laser, 
 wherein the printing of the polymer bonding layer comprises forming an intermediate phase at an interface between the metal structure and the polymer bonding layer, and the intermediate phase comprises a carbon-metal oxide induced by the first laser. 
 
     
     
       2. The method of  claim 1 , wherein the intermediate phase is formed through second-order reaction at the interface between the metal structure and the polymer bonding layer, and is formed when at least any part of a polymer comprised in the polymer bonding layer is melted or sintered and reacts with a part of the metal structure. 
     
     
       3. The method of  claim 2 , wherein the carbon-metal oxide is formed when an organic group of the polymer is thermally or optically decomposed by the first laser and thus a part of the decomposed organic group reacts with a metal or metal oxide on a surface of the metal structure. 
     
     
       4. The method of  claim 2 , wherein the carbon-metal oxide comprises a compound represented by Chemical Formula 1:
   M-O—C  [Chemical Formula 1]
 
 where M denotes a material selected from among inorganic metals and ceramics, and alloys thereof, C denotes a material selected from among polymers comprising carbon and carbon compounds, and O denotes an oxygen inclusion connecting M and C. 
 
     
     
       5. The method of  claim 4 , wherein at least one of M and C is an oxide or an organic group. 
     
     
       6. The method of  claim 1 , wherein, to have a high absorption rate for metals and inorganic materials, the first laser has a wavelength band ranging from 0.1 μm to 10 μm. 
     
     
       7. The method of  claim 1 , wherein the first laser comprises a fiber or yttrium aluminum garnet (YAG) laser. 
     
     
       8. The method of  claim 1 , wherein, to have a high absorption rate for polymers and organic materials, the second laser has a wavelength band ranging from 1 μm to 100 μm. 
     
     
       9. The method of  claim 1 , wherein the second laser comprises a CO 2  or diode laser. 
     
     
       10. The method of  claim 1 , wherein the patterning of the upper surface of the metal structure comprises forming joining patterns by etching parts of the upper surface of the metal structure by using the first laser to induce mechanical anchoring between a metal and a polymer. 
     
     
       11. The method of  claim 1 , wherein the polymer bonding layer comprises a transparent polymer. 
     
     
       12. The method of  claim 11 , wherein the polymer comprises at least one type of thermoplastic polymer resin selected from the group consisting of polylactic acid, acrylonitrile butadiene styrene, polypropylene, polyethylene, polystyrene, polyamide, polycarbonate, polyvinyl chloride, chlorinated polyvinyl chloride, styreneacrylonitrile, acrylonitrile styrene acrylate, polysulfone, polyurethane, polyphenylenesulfide, polyacetal, polyaramid, polyimide, polyester, polyester elastomer, esther acrylate, ethylene copolymer, styrene-butadiene copolymer, and vinyl acetate, or a polymer composite comprising the thermoplastic polymer resin. 
     
     
       13. The method of  claim 1 , wherein the metal structure comprises at least one type of material selected from the group consisting of stain steel, nickel, cobalt, copper, titanium, aluminium, magnesium, silicon, iron, zinc, tungsten, and manganese, or an alloy thereof. 
     
     
       14. The method of  claim 1 , wherein the printing of the polymer bonding layer comprises forming the intermediate phase by inducing chemical reaction between a metal comprised in the metal structure and a polymer comprised in the polymer bonding layer, by irradiating the first laser to the interface between the metal structure and the polymer bonding layer. 
     
     
       15. The method of  claim 1 , wherein an energy density of the first laser to print the polymer bonding layer is lower than an energy density of the first laser to print the metal structure. 
     
     
       16. The method of  claim 1 , wherein an energy density to print the polymer bonding layer is controlled by separately adjusting power of the first laser, a scan speed, a single layer height, and a hatch spacing. 
     
     
       17. The method of  claim 1 , wherein an energy density of the first laser to print the polymer bonding layer has a range in which the polymer bonding layer is not completely carbonized. 
     
     
       18. The method of  claim 17 , wherein the range in which the polymer bonding layer is not completely carbonized is 0.3 times to 0.7 times an energy density of the first laser to print the metal structure. 
     
     
       19. A metal-plastic multi-layered structure comprising:
 a metal structure; 
 a polymer structure provided on the metal structure; and 
 an intermediate phase formed at an interface between the metal structure and the polymer structure, 
 wherein the intermediate phase is formed when at least any part of a polymer comprised in the polymer structure is melted or sintered by a laser and reacts with a part of the metal structure, and 
 wherein the metal-plastic multi-layered structure is produced using the method of  claim 1 . 
 
     
     
       20. A method of producing a metal-plastic multi-layered hybrid structure by using laser three-dimensional (3D) printing, the method comprising:
 printing a metal structure on a substrate by using a first laser; 
 patterning an upper surface of the metal structure by using the first laser; 
 printing a polymer bonding layer on the patterned metal structure by using the first laser; and 
 printing a polymer structure on the polymer bonding layer by using a second laser having a wavelength longer than a wavelength of the first laser, 
 wherein the printing of the polymer bonding layer comprises forming an intermediate phase at an interface between the metal structure and the polymer bonding layer, and the intermediate phase has a 3D structure formed by cross-linking.